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The Serratelli Craft
At Serratelli, every hat begins its journey from the finest materials and is crafted with generations of expertise. Our process is a careful balance of tradition and artistry, where each step is performed with the utmost precision, ensuring a hat that reflects the heritage of Serratelli.
Hat Blocking
The journey begins with hat blocking, where the carefully selected fur blend is shaped into a
basic form. This process not only stiffens and sizes the hat but also lays the groundwork for the
final structure. The blend ensures the hat will hold its shape throughout production.
Shaping the Brim
The brim begins to take its shape using a brim plate. Steam is applied to soften the material,
allowing us to shape and flatten the brim. The hat is then pressed with the brim plate, giving it its
distinctive flat form, ready for further refinement.
Sanding the Crown
After the brim is set, the crown is carefully sanded down. This step smooths and softens the
surface, ensuring a flawless finish that is ready for its signature shape.
Pressing the Crown (Plug Press)
The crown is then pressed using a plug press, giving the crown of the hat its final shape. Whether
traditional or modern, each crown takes on the mold of its design, bringing the hat to life.
Trimming the Brim
Using the brim cutter, we remove any excess material and trim the brim to the desired length.
This is where we find hat roundings—the precious excess material where we got our very start.
Hand Sanding
The hat then undergoes hand sanding, where the brim is hand-beveled and smoothed evenly
throughout. This careful handcrafting ensures a soft, smooth-to-the-touch finish, perfecting the
hat’s silhouette and structure.
Sweatband Branding
At this stage, our Serratelli logo and the X quality is pressed into the sweatband using an
aluminum die. Each sweatband is branded with precision, leaving a lasting mark that symbolizes
our commitment to our craftsmanship.
Flanging the Brim
The brim is carefully flanged using a mold, allowing it to take its final shape and form. This
crucial step ensures the brim holds the exact desired crease.
Sewing in the Sweatband
The sweatband is then cut to size and expertly sewn into the hat, ensuring comfort, fit, and
durability for the wearer.
Placing the Bow
Attention to detail continues as we place the bow into the sweatband. Traditionally sewn at the
back of the hat, the bow signals the back of the hat and adds an elegant finishing touch.
Attaching the Buckle
The final piece of the hatband is the buckle or ribbon which is carefully attached to complete the
band. Each buckle or ribbon adds a touch of refinement to the overall design.
Adding the Tag and Liner
We place the liner in the hat, adding a final layer of comfort and distinction. Then, we carefully put in the American flag and size tag. Every detail is considered, down to the smallest elements.
Final Detailing and Quality Control
Before a hat leaves our workshop, it undergoes meticulous quality control. Every detail is
inspected, from the stitching to the final shape, to ensure it meets our highest standards. The hat
is given one last steaming to perfect its appearance.
Finishing and Packaging
Finally, each hat is carefully packaged, ready to begin its journey to the wearer.
